Bosch Worcester FKT Series User manual

FKT SERIES FLAT PANEL
SOLAR COLLECTORS
IN ROOF MOUNTING FOR WORCESTER SOLAR HEATING SYSTEMS
GB
Installation instructions
63043975.00-1.SD
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About this manual
This installation manual contains important
information for the safe and appropriate installation of
the roof mounted solar collectors.
Notes are included with important information for
situations in which there is no danger for persons or
equipment.
These technical documents should be retained in a
safe place. These may also be inspected at the
manufacturer's premises.
The activities described in the installation manual
assume expertise based on completed vocational
training in gas or water-related installation. Only carry
out these installation steps, if you possess these
skills.
BHand these installation instructions to the
customer.
BExplain to the customer the function and operation
of the related devices.

6 720 613 057 (2006/04) 3
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2 Notes structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.3 Please observe these safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Before installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Other equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Technical documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 Determining space required on roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Roof preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Determining the initial installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Fitting additional roof battens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Collector installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1 Preparing to install the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Fastening the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Collector sensor connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8 Header connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1 Venting through pressure filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.2 Venting through air vent (accessory) on roof . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9 Fitting the connection set for two rows (accessory). . . . . . . . . . . . . . . . . 32
10 Installing the facing panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.1 Lower facing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.2 Side facing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.3 Middle cover strip between two collectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.4 Middle facing panel (when more than one row is being installed) . . . . . . . . . . . . . 37
10.5 Side facing panels on the upper row (if installing more than one row) . . . . . . . . . . 38
10.6 Upper facing panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.7 Covering the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11 Final activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.1 Checking the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.2 Insulating the connection and header pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12 Quick reference guide for two collectors . . . . . . . . . . . . . . . . . . . . . . . . . 42

General information
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1 General information
This chapter details which technical rules and
regulations apply to this installation.
Lightning protection
If the building height (installation height) exceeds 20 m,
and there is no lightning conductor installed, ask your lo-
cal electrical contractor to connect the components on
the roof which conduct electricity with an electrical earth
cable of at least 16 mm2to the earth bonding.
Special measures regarding lightning protection are not
required for building heights (installation heights) of less
than 20 m.
Where there is a lightning conductor system installed,
ask your local electrical contractor to check the inclusion
of the solar heating system into the lightning protection
system.
iUSER NOTE
Observe all standards and guidelines
applicable to the installation and operation
of this system in your country.
UK
Installation work on roofs Connection of thermal solar
heating systems
Installation and equipment of DHW
cylinders
The Health and Safety at Work etc
Act 1974
The Management of Health and Safety
at Work Regulations 1999
The Construction (Health Safety and
Welfare) Regulations 1996
The Construction (Design and
Management) Regulations 1994
The Lifting Operations and Lifting
Equipment Regulations 1998
EN 12976: Thermal solar heating
system and their components (pre-
fabricated systems).
ENV 12977: Thermal solar heating
system and their components
(bespoke systems).
BS 6795: Code of practice for solar
heating systems for swimming pools.
BS5546: 2000 Specification for
installation of hot water supplies for
domestic purposes, using gas-fired
appliances of rated input not
exceeding 70 kW.
BS6700:1997 Specification for
design, installation, testing and
maintenance, of servicing supplying
water for domestic use within
buildings and their curtilages.
Tab. 1 Technical rules for the installation of thermal solar heating systems (selection) in UK
iUSER NOTE
The installation of the Worcester Solar
System must be carried out in accordance
with the relevant requirements for safety,
current IEE wiring regulations, local
building regulations, building standards
(Scotland) (Consolidation) regulations and
by-laws of the local water company and
health and safety document No 635
(Electricity at Work Regulations 1989).
BS 6795: Latest version

Specifications
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2 Specifications
Tab. 2 Specifications
FKT Series solar collectors
Certificates
Length 2070 mm
Width 1145 mm
Height 90 mm
Clearance between collectors 25 mm
Fluid content, portrait version Vf1.43 l
Fluid content, landscape version Vf1.76 l
Gross absorber surface area AG2.37 m²
Net absorber surface area 2.23 m²
Net weight, portrait version m46 kg
Net weight, landscape version m47 kg
Permissible operating pressure
of the collector
pmax 10 bar
DIN
0036

Safety
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3 Safety
This chapter explains the meaning of the notes you will
find in this manual and provides general safety instruc-
tions for safe and trouble-free operation.
The installation-specific safety and user notes next to
the appropriate installation steps are found here.
Carefully read the safety instructions before commenc-
ing the installation.
Severe injury and even death, as well as material losses
and environmental damage, may follow if you ignore
safety instructions.

Safety
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3.1 Correct use
This installation set holds the thermal solar collectors
(portrait and landscape), which are installed on pitched
roofs with a pitch angle of 25° to 65°.
Operating conditions
Only erect the installation set on roofs whose construc-
tion can support the weight. If necessary, consult a
structural engineer or a roofer.
The installation set is suitable for a max. standard
snow load of 3,8 kN/m² and an installation height of
max. 20 m.

Safety
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3.2 Notes structure
Two levels are identified by signal terms:
Further symbols identifying dangers and user notes:
WARNING!
RISK TO LIFE
Identifies possible dangers which might
lead to serious injury or death if
appropriate care is not taken.
CAUTION!
RISK OF INJURY/SYSTEM DAMAGE
Identifies potentially dangerous situations,
which might lead to mild or slight injuries
or to material losses.
WARNING!
RISK TO LIFE
from electric shock.
iUSER NOTE
Tip for the optimum utilisation and setting
of the products plus other useful
information.

Safety
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3.3 Please observe these safety
instructions
WARNING!
RISK TO LIFE
through a fall or falling parts.
BEnsure you have the correct safety
equipment for working on roofs.
BTake appropriate action to prevent
accidents when working on roofs.
BWhilst working on the roof, take all
necessary precautions against a
possible fall.
BAlways wear your personal protective
clothing and safety equipment.
BAfter completing the installation, always
check the secure positioning of the
installed set and that of the collectors.
CAUTION!
RISK OF INJURY
Injury and operating faults can result from
making changes to the system
construction.
BNever change the system construction.
CAUTION!
RISK OF INJURY
Some parts may cause burns, if the
collector and installation materials are
exposed to solar radiation for longer
periods of time.
BAlways wear your personal protective
clothing and safety equipment.
BCover the collector (e.g. with a covering
sheet – available as an accessory) and
the installation material during the
installation as protection against high
temperatures resulting from solar
irradiation.

Before installation
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4 Before installation
4.1 General notes
Make yourself familiar with the on-site conditions and lo-
cal regulations before commencing the installation.
Check
Bthe delivery for completeness and perfect condition.
Bthe optimum arrangement of the solar collectors.
Take account of the direction of the sunlight (angle of
inclination, southerly direction). Avoid the shade of
high trees or structures and match the collector array
to the shape of the building (e.g. aligned with win-
dows, doors, etc.).
iUSER NOTE
It is recommended that the services of a
roofing company, who are experienced in
working on roofs and will be fully aware of
the risks of working at height are
considered.
Fig. 1 General overview of collector pair – in roof mounting
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CAUTION!
RISK OF INJURY
If the collector and its installation material
is left exposed to the sunlight for a long
period, the parts will become hot and may
cause burns.
BWear protective clothing.
BCover the collector (e.g. with
a covering sheet – available as an ac-
cessory) and the installation material
during the installation as protection
against high temperatures resulting
from solar irradiation.
iUSER NOTE
Only use OEM components and replace
any damaged or faulty parts immediately.
iUSER NOTE
Remove broken tiles, shingles or plates in
the area of the collectors and replace
them.

Before installation
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4.2 Component description
4.2.1 Installation set for the collectors
The installation sets are for fixing the collectors in place
and sealing them.
The lower facing panels (Fig. 2, Item 6, 9and 10) are
designed for slate/shingle roofs with no flashing.
If installing more than one row of collectors, basic and
extended installation sets are delivered separately.
Fig. 2 1 basic set for the outer collectors and 1 extended set for the middle collector (portrait, single row)
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4
4
5
14
15
8
9
10
11
12
17
18
13
19
Basic installation set for both outer collectors in
one row (Fig. 2):
Extended installation set for each additional
collector (Fig. 2):
Item 1: Upper left-hand facing panel 1 ×Item 2: Upper middle facing panel 1 ×
Item 3: Upper right-hand facing panel 1 ×Item 4: Clips (4 spares) 6 ×
Item 4: Clips 12 ×Item 7: Anti-slip protection bar 1 ×
Item 5: Side facing panel, right 1 ×Item 8: Anti-slip protection
Item 6: Lower facing panel, right 1 ×(x 3 for horizontal collectors) 2 ×
Item 7: Anti-slip protection bar 2 ×Item 9: Lower facing panel, middle 1 ×
Item 8: Anti-slip protection Item 11: Roll of sealing tape 1 ×
(x 6 for landscape collectors) 4 ×Item 14: Double-sided clamp 3 ×
Item 10: Lower facing panel, left 1 ×Item 15: Cover strip 1 ×
Item 11: Roll of sealing tape 1 ×Item 19: Pan tile overlay 1 ×
Item 12: Side facing panel, left 1 ×
Item 13: Underlay plate, left 3 ×
Item 14: Double-sided clamp 3 ×
Item 15: Cover strip 1 ×
Item 16 Screw 6×40 with washer 6 ×
Item 17: Single-sided clamp 6 ×
Item 18: Underlay plate, right 3 ×
Item 19: Pan tile overlay 2 ×

Before installation
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4.2.2 Pipework connections
For the pipework connection a connection kit and a con-
nection set between the collectors will be required.
Connection kit, per collector array (Fig. 3)
Connection set between the collectors, for each
collector (in two corner protectors, Fig. 4)
Fig. 3 Connection kit and connection set (illustration shows 2 portrait collectors)
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Item 2: Pipe clip 2 ×Item 6: Size 5 spanner 1 ×
Item 3: Connecting pipe (insulation not shown) 2 ×Item 7: End cap 2 ×
Item 4: Insulation for corrugated pipe Item 8: Sensor bush plug, not shown 1 ×
connector 710 mm 1 ×
Item 5: Fitting for collector sensor 1 ×
Fig. 4 Two corner protectors with one connection set
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Item 1: Corrugated pipe connector 2 ×
Item 2: Pipe clip 4 ×

Before installation
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4.3 Other equipment
–Spirit level
–Plumb line
–Filling pump
–Vest harness with safety rope
–Pipe insulation
–Scaffolding
–Roofing ladder
–Crane or mobile hoist
–Cordless screwdriver and drill (Ø4 mm)
–Size 10 and 8 spanners (incl. 80 mm extension)
4.4 Transport and storage
Please ensure that the corner protectors are re-
tained. They contain pipework connection pieces
which are required for installation.
All components are protected by transport packaging.
Transport protection for collector connections
The collector connections are protected against damage
by plastic caps.
Storage
The collectors must be stored in dry conditions.
iUSER NOTE
Dispose of the transport packaging in
an environmentally friendly recycling sys-
tem.
Fig. 5 Plastic caps on collector connections
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CAUTION!
SYSTEM DAMAGE
through damaged sealing faces.
BDo not remove the plastic caps (Fig. 5,
Item 1) until immediately prior to in-
stallation.
iUSER NOTE
Do not store collectors outside without
protection from the rain.

Before installation
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4.5 Technical documentation
The solar heating system consists of various compo-
nents (Fig. 6). Installation, operation and maintenance
documentation is provided for each component. Acces-
sories may be accompanied by a separate document.
Fig. 6 Solar heating system components and technical
documentation
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1
3
4
Item 1: Collector: instructions for in-roof installation
are enclosed with the connection kit
Item 2: Pump station: instructions enclosed with the
complete station
Item 3: Solar Controller: instructions are enclosed
with the controller.
Item 4: DHW Cylinder: instructions enclosed with the
DHW cylinder.

Before installation
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4.6 Determining space required on roof
Please note the following minimum space requirements.
Dimension A and B
Area required for the collector array, incl. facing panels.
Dimension C
At least two tiles to the roof or chimney. Otherwise there
is a risk of damaging the tiles, particularly if the tiles are
laid in mortar.
Dimension D
Roof overhang including gable wall thickness.
Dimension E
Minimum 30 cm for fitting the connection cables in the
attic.
Dimension F
Minimum 40 cm for fitting the connection cables in the
attic.
Please note that the air vent must be the highest point of
the system.
Fig. 7 Clearances to be observed
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Space requirements for portrait collectors: Space requirements for landscape collectors:
Number of collectors Dimension A Dim. B Number of collectors Dimension A Dim. B
2 2.67 m 2.80 m 2 4.52 m 1.87 m
33.84 m 2.80 m 36.61 m 1.87 m
4 5.01 m 2.80 m 4 8.71 m 1.87 m
56.18 m 2.80 m 510.80 m 1.87 m
6 7.41 m 2.80 m 6 12.90 m 1.87 m
78.52 m 2.80 m 714.99 m 1.87 m
8 9.69 m 2.80 m 8 17.09 m 1.87 m
910.86 m 2.80 m 918.96 m 1.87 m
10 12.03 m 2.80 m 10 21.28 m 1.87 m
Tab. 3 Space requirement for portrait installed collectors
(incl. facing panels all around)
Tab. 4 Space requirement for landscape installed panels
(incl. facing collectors all around)

Roof preparations
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5 Roof preparations
WARNING!
RISK TO LIFE
Whilst working on the roof, take all neces-
sary precautions against a possible fall.
WARNING!
RISK OF INJURY
through a fall or falling parts.
BTake appropriate action to prevent ac-
cidents when working on roofs.
BAlways wear personal protective cloth-
ing and safety equipment.

Roof preparations
6 720 613 057 (2006/04) 17
5.1 Determining the initial installation positions
Before installation, carefully determine the initial posi-
tions.
Initial horizontal position
BDetermine dim. X (distance between the tiles that lie
on the side facing panels, Fig. 8, Item 1) on the roof
and mark it on the roof.
Original vertical position
BDetermine the lowest row of tiles (Fig. 8, Item 2 tak-
ing dimension B into account (Fig. 8).
Number
Collectors
Dimension A Dimension X
portrait landscape portrait landscape
1 1.50 m 2.42 m 1.32 m 2.24 m
22.67 m 4.52 m 2.49 m 4.34 m
3 3.84 m 6.61 m 3.66 m 6.43 m
45.01 m 8.71 m 4.83 m 8.53 m
5 6.18 m 10.80 m 6.00 m 10.62 m
67.41 m 12.90 m 7.23 m 12.72 m
7 8.52 m 14.99 m 8.34 m 14.81 m
89.69 m 17.09 m 9.51 m 16.91 m
9 10.86 m 18.96 m 10.68 m 18.78 m
10 12.03 m 21.28 m 11.85 m 21.10 m
Tab. 5 Width of collector array, incl. facing panels (dim. A)
and distance between the tiles (dim. X)
iUSER NOTE
If possible, plan in such a way that the
tiles are only cut on the right side of the
collector array, but always in a tile trough.
After cutting, at least half of the tile should
still remain.
Number
of rows
Dim. B
portrait landscape
1 2.80 m 1.87 m
25.02 m 3.17 m
3 7.25 m 4.47 m
49.47 m 5.77 m
Tab. 6 Height of collector array, incl. facing panel (dim. B)
iUSER NOTE
If pan tiles need to be shortened, only cut
the upper pan tiles.
Fig. 8 Determining the exact position of the collector array
A
B
> 80 mm
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X
> 80 mm
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2

Roof preparations
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5.2 Fitting additional roof battens
When laying the facing panels and collectors in place,
there will have to be additional roof battens of equal
height to those already on the building.
Length of additional roof battens
The minimum length of the additional battens (Fig. 9,
Item 2 is the width of the collector array (Table 5,
page17, dim. A) plus approx. 10 cm for the side clips
(Fig. 9, Item 1).
iUSER NOTE
As an alternative to additional roof bat-
tens, those already present around the
collector array area can be adjusted to the
same dimensions as the additional roof
battens.
These instructions describe installation
using additional roof battens.
CAUTION!
BUILDING DAMAGE
from leaks in the roof.
BFasten batten butt joints to the joist
or ensure that they are adequately se-
cure, e.g. by fastening them to the al-
ready existing roof battens (Fig. 9,
Item 3 and Fig. 13, Item 2).
Fig. 9 Length of additional roof battens (here: first lower roof batten with anti-slip protection)
Item 1: Clip
Item 2: Additional roof battens
Item 3: Joining the additional roof battens
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X
A
2
3
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Roof preparations
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5.2.1 Fitting anti-slip protection devices to first
additional roof batten
Due to limited space it may be possible for the anti-slip
protection devices to be fitted directly on to the roof. If so
they should be pre-assembled on the ground and fitted
to the first additional roof batten.
BFasten two anti-slip protection devices (Fig. 10,
Item 1) to the end of the strip of wood provided, using
screws 4×10 (Fig. 10, Item 2).
BPlace pre-assembled anti-slip protection device to
the first additional roof batten (Fig. 11, Item 2), and
fasten using two screws 4×40 (Fig. 11, Item 1) (ob-
serve measurements).
5.2.2 Fitting additional roof battens
Fig. 10 Pre-assembling anti-slip protection devices with strip
of wood
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iUSER NOTE
For landscape installation, 3 anti-slip pro-
tection devices (Fig. 10, Item 1) must be
fastened to one strip of wood (2 on the
outside, 1 in the middle).
Fig. 11 Fasten anti-slip protection devices to roof batten
(measurements in mm, value in brackets =
horizontal version)
270800 (1720)
370
1
2
2
Fig. 12 Levelling the joists
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CAUTION!
BUILDING DAMAGE
from leaks in the roof.
BIf the joists are at different levels, they
must all be levelled (Fig. 12).
iUSER NOTE
When fitting the roof battens, make sure
they are level (use spirit level).

Roof preparations
6 720 613 057 (2006/04)
20
Installing one row
BAttach first roof batten with the anti-slip protection de-
vices (Fig. 14, Item 1).
BAttach second roof batten for the lower side clamp
(Fig. 14, Item 2).
BAttach third roof batten for the upper side clamp
(Fig. 14, Item 3).
BAttach fourth roof batten for supporting the polysty-
rene wedge of the upper facing panels (Fig. 14,
Item 4).
BAttach fifth roof batten for supporting the upper facing
panels (Fig. 14, Item 5).
BAttach sixth roof batten for supporting and fastening
the upper facing panels (Fig. 14, Item 6).
Fig. 13 Moving roof battens around the collector array area
Item 1: Moved roof batten
Item 2: Fastening for roof batten ends (counter batten)
Item 3: Collector array (outside)
Item 4: Joist
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iUSER NOTE
If an additional roof batten (Fig. 13,
Item 1) has to be fitted near a pre-existing
one, the pre-existing one must be moved
near to the collector array (Fig. 13,
Item 3) and adequately fastened (Fig. 13,
Item 2).
The pan tiles on the side facing panels
MUST be covered.
Fig. 14 Distances between additional roof battens when installing one row (measurements in mm,
values in brackets = landscape version)
160 200 - 230
1860 - 1890 (940 - 970)
2120 (1200)
2490 - 2520 (1570 - 1600)
2240 - 2270 (1320 - 1350)
160
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